A single light cannon module was built up as per the initial assembly instructions and then put through water ingress testing simulating rainfall. The unit continued to operate throughout testing in multiple orientations. On disassembly, the light cavity was found to be dry, but significant water ingress was found in the power supply cavity. Further work is required to identify the root cause of the leakage and develop a solution.
The IP test unit was placed in the shower at the CRS Electronics Sales and Research location. The unit was placed on a pedestal to ensure that the shower water flow was incident on the full unit. In each of several configurations, the unit was placed under the shower flow for approximately 30 minutes. The fixture was then powered up using a GFCI-protected extension cord throughout testing. Visual inspection during each stage of the test confirmed that the light cavity remained dry.
The initial testing configuration consisted of the unit oriented horizontally, with the light output facing the shower faucet. The second stage was carried out with the unit vertically oriented with the fans on the bottom, Image 1, and the third configuration was oriented vertically with the fans on the top. The fourth stage consisted of the unit facing down, Image 2, the fifth stage with the unit facing up, Image 3, and the final stage tested with the unit in a vertical configuration, with the fans on the top. The total testing time while under continuous water spray was in excess of three hours.
After being subject to more than the hours of continuous spray, the test unit was removed from the shower and dried off. On visual inspection of the light cavity, the moisture sensitive strips remained blue indicating that the light cavity remained sealed, Image 4. The end caps were removed, and visual inspection showed significant water ingress in the power supply cavity, Images 5 and 6. Visually, an imprint of the extrusion profile was present on the gaskets of both end caps. On inspection, the poke-thru grommets appear to be the most likely cause of leakage, with the rear grommet potentially lifted from the sealing surface, Images 7 and 8. On the AC-side, the grounding screw and cable entry appear well-sealed, Images 9 and 10.
The main candidates for the water ingress points are inadequate sealing on the end-cap gasket and poke-thru sealing grommets. Visually, the cable gland and grounding screw appear to be well sealed, but this should be tested. Further testing is planned to identify the root cause of the leakage and develop a strategy to mitigate the problem.